Component Tests and General Diagnostics

When diagnosing an electrical system that uses Metri-Pack 150/280/480/630 series terminals, it is important to check terminal contact between a connector and component, or between in4ine connectors, before replacing a suspect component.

Frequently, a diagnostic chart leads to a step that reads Check for proper connection...." Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination is caused by the connector halves being improperly connected, a missing or damaged connector seal, or damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or an intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Use the following procedure to check terminal contact.

1. Separate the connector halves.
2. Inspect the connector halves for contamination. Contamination results in a white or green buildup within the connector body or between terminals, causing high terminal resistance, intermittent contact or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals and connector body.
3. Using an equivalent male terminal from the Terminal Repair Kit J 38125-A, check the retention force of the female terminal in question by inserting and removing the male terminal to the female terminal in the connector body. Good terminal contact requires a certain amount of force to separate the terminals.
4. Using an equivalent female terminal from the Terminal Repair Kit J 38125-A, compare the retention force of this terminal to the female terminal in question by joining and separating the male terminal to the female terminal in question. If the retention force is significantly different between the two female terminals, replace the female terminal in question, using a terminal from the Terminal Repair Kit J 38125-A.

If a visual/physical check does not reveal the cause of the problem, the vehicle may be able to be driven with a DVOM connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit.